After reviewing many of the posts here regarding the potential sources of oil leaks on the 7.3L diesel (mine's an '01 model), I never came across what I eventually found to be source of my leak.
Word of caution: Do not remove the downward facing plug on the bottom of the HPOP, Ford's TSB for this repair says removing it will damage your HPOP $$$. The one you can remove is on the back, near the fuel bowl drain.
My leak started out slow and within a week or so had turned to a torrential downpour that nicely waterproofed the entire underside of my truck. After a brief search, I found that the "end plug" as Ford calls it on the back of the HPOP (high pressure oil pump) used to have an O-ring on it, but now only scraps of an O-ring remained. It was much easier to spot the oil running from the 18mm plug on the HPOP when the engine was cold (rather than spraying vigorously when the oil was warm).
I acquired the new O-ring kit from the dealer (part # 2C3Z-9G804-AB), and hope to have the problem resolved in short order. Anyways, just wanted to put it out there that this End Plug can be a source of the problem, since it doesn't appear it's discussed much and if it happened to mine...
Last edited by Redsundevil; 01-08-2007 at 03:33 PM.
Funny you should mention it. I just picked min '03 up from the dealer who replaced the o-ring in mine. I just got back from a trip to TX and noticed a puddle. I didn't have time to explore so I needed an oil change anyway and took it it. They got it fixed and it was covered under warranty except for the $100 dedectible (which was probably about what it cost anyway ). Anyway, it was no biggie and it's fixed.
Thank you very much for your input Miller. I thought it was gradually sounding better as it idled but didn't want to take the chance of letting it run on like an off-balance washing machine if it wasn't going to help. As it turns out, it worked through the rough running condition in a couple miles and all is good.
Now I just hope to find that the oil falling onto the ground is just the residual oil from the previous leak. You guys are awesome, thanks for your support of ford-trucks.com
The end plug on the HPOP is an 18MM threaded bolt that looks like a larger version of any drain plug you've ever encountered. As you'll likely see in the $29 o-ring kit you buy from Ford, the plug should be torqued to 25 ft-lbs upon reinstallation (along with some loctite).
I had considered trying to locate some generic o-rings that were the same size, but now that I've seen the o-ring that comes in the kit, I don't think I would advise someone to go this route. The rubber in the new O-ring kit seems to be a much harder compound than most run-of-the-mill O-rings I've seen. So spend the $29 here (assuming this is the problem and hopefully you won't have to scrub your driveway every week.
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